Portable saw table assembly

ABSTRACT

The subject invention provides a portable saw table assembly for cutting a material longitudinally, laterally, and at various angles thereto. The assembly includes a first and a second table rail being parallel and spaced from each other and each extending between a proximal end and a distal end. A saw rail is moveably supported by the first and the second table rails for moving longitudinally along the table rails between the proximal and the distal ends and a mounting plate is moveably supported by the saw rails to allow movement of the mounting plate laterally along the saw rail between the first table rail and the second table rail. A saw plate is rotateably supported by the mounting plate for carrying a saw to cut the material. A guide bar is disposed diagonally relative to the first and the second table rails and engages the saw plate to guide the saw plate diagonally in response to simultaneous movement of the saw rail longitudinally and the mounting plate laterally.

RELATED APPLICATIONS

This application is a Continuation of U.S patent application Ser. No.10/448,679 filed on May 30, 2003, now U.S. Pat. No. 7,555,976 whichclaims priority to U.S. Provisional Patent Application No. 60/384,298,which was filed on May 30, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention relates to a portable saw table assembly forcutting a material longitudinally, laterally, and at various anglesthereto.

2. Description of the Related Art

Various portable saw table assemblies for cutting a materiallongitudinally, laterally, and at various angles thereto are known tothose skilled in the art. The assemblies typically include a first tablerail and a second table rail being parallel and spaced from each otherand each extending between a proximal end and a distal end. A saw railis moveably supported by the first and the second table rails for movinglongitudinally along the table rails between the proximal and the distalends and a mounting plate is moveably supported by the saw rail to movethe mounting plate between the first table rail and the second tablerail. The assemblies also include a saw plate rotateably supported bythe mounting plate for carrying a saw to cut the material. The saws aretypically attached to long arms that pivot to cut various angles intothe material.

One such assembly is shown in U.S. Pat. No. 4,516,453 to Parham, Jr. The'453 patent discloses a saw table assembly having a table rail slideablyreceiving a first end of a saw carriage. The other end of the sawcarriage is rotateably fixed to the table assembly to allow the sawcarriage to pivot to cut a material at various angles. When the sawcarriage is pivoted, the first end slides within the table rail. Boltssecure the first end to the table rail to prevent the saw carriage fromshifting while cutting the material. Since the saw rails have to be longenough to extend along the diagonal, the saw rails may flex when cuttingthe material. The flexing of the saw rails produces inaccurate cuts inthe material. The saw rails also lose their rigidity causing the saw torock from side to side thereby producing inaccurate cuts. Also, the sawrails project over the edges of the table making the saw awkward to use.

Another assembly shown in U.S. Pat. No. 4,802,399 to Olson discloses asaw table assembly having a first and a second table rails supporting apair of saw rails. The saw rails support a saw carriage for cutting amaterial. The saw rails are fixed to the table rails to preventlongitudinal movement of the saw carriage. The saw carriage moveslaterally along the saw rails to cut the material. The saw carriage isrotateable between a lateral position and a longitudinal position to cutthe material. Since the saw rails are fixed to the table rails, in orderto produce a longitudinal cut, the '399 patent utilizes rollers mountedon the second table rail such that the material moves longitudinallywhile the saw remains fixed. The table assembly can only cut thematerial longitudinally and laterally and not diagonally.

Yet another assembly shown in U.S. Pat. No. 3,866,496 to Payne et al.discloses a saw table assembly capable of cutting material diagonally.The saw table assembly includes a first and a second table rail moveablysupporting a pair of saw rails. The saw rails also moveably support asaw carriage for moving between the table rails to cut the materiallaterally. The saw carriage includes a saw plate that is rotateable forrotating a saw between lateral and longitudinal. The saw rails connectto the table rails with support plates, which can be positioned alongthe table rails for cutting the material diagonally. To cut the materialdiagonally, the support plates are positioned at their respectivepositions and locked in place. This aligns the saw at the desired anglewith the saw rails being diagonal and the saw is moved along the sawrails to produce the diagonal cut. However, one disadvantage of such anassembly is that the support plates must be aligned each time adifferent angle cut is desired. After cutting the first angle, each ofthe support plates is then moved to another position to cut a differentangle. Also, since the saw is carried by the saw rails and the saw railsmust be long enough to extend along the diagonal, the saw rails may flexwhen cutting the material. If the saw rails are made of a strongermaterial to prevent flexing, then the saw table assembly becomes heavierand makes it less portable. Also, the saw rails project over the edgesof the table making the saw awkward to use.

The related art assemblies are characterized by one or moreinadequacies. Accordingly, it would be advantageous to provide a sawtable assembly that is lightweight, portable, and convenient to use forprecisely and accurately cutting material at various angles.

BRIEF SUMMARY OF THE INVENTION AND ADVANTAGES

The subject invention provides a portable saw table assembly for cuttinga material longitudinally, laterally, and at various angles thereto. Theassembly includes a first table rail and a second table rail beingparallel and spaced from each other and each extending between aproximal end and a distal end. A saw rail is moveably supported by thefirst and the second table rails and disposed perpendicular to the firstand the second table rails for moving longitudinally along the tablerails between the proximal and the distal ends. The saw rail moveablysupports a mounting plate such that the mounting plate moves laterallyalong the saw rail between the first table rail and the second tablerail. A saw plate is rotateably supported by the mounting plate forcarrying a saw to cut the material. The assembly further includes aguide bar disposed diagonally relative to the first and the second tablerails and engaging the saw plate to guide the saw plate diagonally inresponse to simultaneous movement of the saw rail longitudinally and themounting plate laterally.

The subject invention overcomes the inadequacies that characterize therelated art assemblies. Specifically, the subject invention allows thematerial to be precisely cut at various angles. Since the saw rails donot have to extend along a diagonal, the saw rails do not flex therebyproducing a more accurate cut. Also, the assembly is more convenient foruse since the saw rails to extend from the table as does the related artassemblies. Further, the guide bar is moveable between predeterminedangles, or pitches, to allow for quick and efficient cutting of thematerial. The subject invention can also be operated by a single userbecause it is lightweight and portable.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of a saw table assembly according to thesubject invention;

FIG. 2 is a perspective view of a pair of saw rails extending between afirst and a second table rails having a mounting plate supported by thesaw rails and a saw plate supported by the mounting plate without a sawmounted to the saw plate;

FIG. 3 is a perspective view of a saw mounted to the saw plate in alateral direction for cutting the material laterally;

FIG. 4 is a perspective view of the saw mounted to the saw plate in alongitudinal direction for cutting the materially longitudinally; and

FIG. 5 is a perspective view of the saw table assembly having a guidebar extending between the first table rail and the second rail forcutting a material on an angle;

FIG. 6 is a perspective, close-up view of the guide bar being supportedby the first table rail and an angle rail having a bar locator therein;

FIG. 7 is a perspective view of the guide bar supported by the anglerail and the second table rail;

FIG. 8 is a perspective view of a connector supported by a saw plate forengaging the guide bar to guide the saw plate diagonally;

FIG. 9 is a perspective view of a material stop supported by the firsttable rail for positioning the material to produce accurate cuts; and

FIG. 10 is a perspective view of the saw table assembly being foldedinto a portable position.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views, a portable saw tableassembly for cutting a material longitudinally, laterally, and atvarious angles thereto is shown generally at 20 in FIG. 1. The saw tableassembly 20 is particularly useful for cutting siding materials forbuildings, such as vinyl siding. However, it would be equally useful forcutting other materials, such as wood. The saw table assembly 20 may beformed of any type of material capable of supporting the material to becut, but is preferably aluminum to allow for easy transportation. Othermetals may also be used so long as the assembly 20 is lightweight andportable.

The assembly 20 includes a first table rail 22 and a second table rail24 being parallel and spaced from each other and each extending betweena proximal end 26 and a distal end 28. The first and the second tablerails 22, 24 are preferably C-shaped to define a channel 30 extendinglongitudinally along the length of each of the first table rail 22 andthe second table rail 24 and also defines a slot 32. A lateral support34 extends between the first table rail 22 and the second table rail 24forming a table surface 36 for supporting the material to be cut. Asillustrated in the figures, a plurality of lateral supports 34 extendbetween the first and the second table rails 22, 24. The table surface36 may be formed from plywood supported on the lateral supports 34 andextending from the proximal end 26 to the distal end 28.

A saw rail 38 is moveably supported by the first and the second tablerails 22, 24 for moving longitudinally along the table rails 22, 24between the proximal and the distal ends 26, 28. Preferably, a pair ofsaw rails 38 extend perpendicularly between the first and the secondtable rails 22, 24. The saw rails 38 engage the channel 30 in the firstand the second table rails 22, 24 to slide longitudinally. In order toslide, the saw rails 38 may include wheels, bearings, or the like 40 forallowing fluid movement of the saw rails 38 in the channels 30. However,it is to be appreciated that the saw rails 38 may slide without anywheels, bearings, or the like 40 by being sized precisely to fit withinthe channels 30 to allow movement. The saw rails 38 are therefore ableto slide the entire length of the table assembly 20 from the proximalend 26 to the distal end 28. The saw rails 38 may be removed from thefirst and the second table rails 22, 24 at either of the proximal ordistal ends 26, 28 by sliding out the saw rails 38 from the channels 30.

Referring to FIG. 2, each of the saw rails 38 also define a channel 42for moveably supporting a mounting plate 44 to allow movement of themounting plate 44 laterally along the saw rail 38 between the firsttable rail 22 and the second table rail 24. Preferably, the mountingplate 44 is slideably received within the channels 42 of the saw rails38. The mounting plate 44 is then able to slide the width of the tablebetween the first table rail 22 and the second table rail 24. Themounting plate 44 may also include wheels, bearings, or the like 46 forsliding within the rails. The mounting plate 44 is generally rectangularshaped and extends between the saw rails 38. The mounting plate 44 hasan opening for allowing the saw to extend there through to cut thematerial.

A plate clamp 50 extends from the mounting plate 44 for engaging atleast one of the saw rails 38 for fixing the position of the mountingplate 44 between the first table rail 22 and the second table rail 24.The plate clamp 50 locks the mounting plate 44 to prevent lateral motionof the mounting plate 44 while moving the saw rails 38 longitudinally.When the plate clamp 50 is disengaged, the mounting plate 44 slidesfreely within the saw rails 38.

The subject invention further includes a saw plate 52 rotateablysupported by the mounting plate 44 for carrying a saw to cut thematerial, as shown in FIGS. 3 and 4. The saw that is preferably usedwith the table assembly 20 is a hand saw having a saw guide as is knownin the art of saws. The saw plate 52 defines an aperture 60 throughwhich a blade of the saw extends. A plurality of plate locks 62 extendinto the saw plate 52 for securing the saw thereto. The plate locks 62may include a lip 63 that engages the saw guide of the saw to provideadditional support for securing the saw to the saw plate 52. To mountthe saw to the saw plate 52, the plate locks 62 are slide open and thesaw is positioned therein. The plate locks 62 are then slide intoengagement with the saw guide to secure the saw to the saw plate 52. Thelips 63 of the plate locks 62 also engage the saw guide. Each of theplate locks 62 may be locked in the position to prevent the saw frommoving.

The saw plate 52 has a plurality of detents 64 which correspond to apredetermined angle, or pitch, for cutting the material. The saw plate52 may rotate on the mounting plate 44 on bearings or the like (notshown). A latch mechanism 66 is mounted to the mounting plate 44 tosecure the saw plate 52 at the angle and to prevent the saw plate 52from rotating. The latch mechanism 66 engages the detent 64 to fix theposition of the saw at the predetermined angle. As shown in FIG. 3, thesaw plate 52 is positioned such that the material is cut at a ninetydegree angle with respect to the first table rail 22 by moving themounting plate 44 laterally. Whereas in FIG. 4, the saw plate 52 ispositioned such that the material is cut at a one hundred and eightydegree angle with respect to the first table rail 22 by moving the sawrails 38 longitudinally.

A saw clamp 68 may also be mounted to the saw plate 52 for securing thesaw to the saw plate 52. Once the plate locks 62 have been positioned tofit the saw, the saw is positioned on the saw plate 52. The saw clamp 68is then locked into place to secure the saw. The plate locks 62 includethe lip 63 engaging the saw guide. The saw clamp 68 and plate locks 62allow for efficient removal of the saw from the saw plate 52. Further,only some of the plate locks 62 may engage the saw guide of the saw,while the others only position the saw to the saw plate 52.

Referring to FIG. 5, a guide bar 70 is disposed diagonally relative tothe first and the second table rails 22, 24 and engages the saw plate 52to guide the saw plate 52 diagonally in response to simultaneousmovement of the saw rail 38 longitudinally and the mounting plate 44laterally. In one embodiment, the guide bar 70 defines a groove 72 forengaging the saw plate 52. The angle rail 76 may be conveniently storedtelescopically in one of the longitudinal supports or the rails. The sawplate 52 includes a connector 74 for engaging the groove 72 of the guidebar 70 to move the saw plate 52 diagonally. The latch mechanism 66 mayonly secure the saw plate 52 in the 180 degree position and the 90degree position, while the connector 74 and the guide bar secure the sawin the angles therebetween.

When cutting the material at certain angles, or pitches, an angle rail76 may be required, as shown in FIGS. 6 & 7. The angle rail 76 issupported by and extends between the first and the second table rails22, 24 for supporting the guide bar 70 at various angles. Preferably,the angle rail 76 also defines a slot 78, for use as described below.When the guide bar 70 is positioned on only the first and the secondtable rails 22, 24, only certain pitches may be achieved. Therefore, byusing the angle rail 76, various other pitches may be obtained.

In order to position the guide bar 70 diagonally and to prevent theguide bar 70 from moving while cutting diagonally, a bar locator 80 issupported by one of the first and the second table rails 22, 24 andengages the guide bar 70. The bar locator 80 is moveable within thefirst and the second table rail 24. Depending upon the desired pitch ofthe material, the bar locator 80 slides to position the guide bar 70 atvarious angles between a lateral direction and a longitudinal direction.Preferably, the subject invention incorporates a pair of bar locators 80engaging each of the first and the second table rails 22, 24. Utilizingmore than one bar locator 80 provides more accurate cuts; however, thesubject invention may use none, one, or more than two. For pitchesbetween 4/12 and 12/12, one bar locator 80 is positioned on the firsttable rail 22 and the other is on the second table rail 24. For pitchesless than 4/12, one of the bar locators 80 engages one of the first andthe second table rails 22, 24 and the other of the bar locators 80engages the angle rail 76. Alternately, the subject invention mayinclude a third bar locator 81 engaging the angle rail 76 such that theguide bar 70 engages one of the pair of bar locators 80 and the thirdbar locator 81, without having to remove one from the first or thesecond table rails 22, 24. It is to be understood that these pitches maybe varied by modifying the size or shape of the table without deviatingfrom the subject invention.

Each of the bar locators 80, 81 may include posts 82 extending upwardlyfrom the bar locators 80, 81 for engaging and positioning the guide bar70 at various angles. A locking mechanism 84 engages each of the barlocators 80, 81 for locking the bar locators 80, 81 in the slots 32, 78of the first and the second table rail 24 and the angle rail 76,respectively. In order to precisely and quickly change the position ofthe bar locators 80, 81, angle indicators 83 are present on at least oneof the first and the second table rails 22, 24, the saw rail 32, and theangle rail 76. The bar locators 80, 81 are moved to the desired angleindicators 83 and locked into place by the locking mechanism 84. Theguide bar 70 pivots about the posts 82 to change the angle of the cut inthe material. The guide bar 70, when not being used, may be convenientlystored telescopically in one of the rails or longitudinal supports.

The connector 74, shown in FIG. 8, may be supported on the saw plate 52for being received in the groove 72 of the guide bar 70 to guide the sawas it moves along the guide bar 70. After the guide bar 70 has beenpositioned, the connector 74 is connected to the guide bar 70. As themounting plate 44 is moved laterally and the saw rails 38 are movedlongitudinally, the connector 74 follows along the guide bar 70 toachieve the desired pitch in the material. Since the saw is beingcarried by the mounting plate 44, the first and the second table rails22, 24, and guided by the guide bar 70, there is little or no flexing ofthe saw rails 38 to produce inaccurate cuts.

In operation, the user positions one bar locator 80, 81 and then theother bar locator 80, 81 in the respective slots 32, 78, as describedabove, and locks the locking mechanism 84 so that the bar locators 80,81 do not move. Next, one end of the guide bar 70 is mounted onto one ofthe bar locators 80, 81 such that the post 82 engages the guide bar 70.The other end of the guide bar 70 is then moved into engagement with theother bar locator 80, 81 such that the post 82 engages the guide bar 70.The guide bar 70 may engage the bar locators 80, 81 by other means otherthan the posts 82 described, such as clamps or screws, without deviatingfrom the subject invention.

Referring to FIG. 9, after the guide bar 70 is positioned, the saw plate52 is rotated so that the connector 74 contacts the groove 72 of theguide bar 70. In order to follow the angle of the guide bar 70, themounting plate 44 and the saw rails 38 simultaneously slide in theirrespective channels 30, 42 to form the angled cut.

A measuring rod 86 may be supported on the first and the second tablerails 22, 24 and extends between the proximal and distal ends 26, 28. Amaterial stop 88 may be slideably carried on the measuring rod 86 suchthat the material stop 88 is moved along the measuring rod 86 to allowthe material to be cut having a predetermined length that is indicatedon the measuring rod 86 itself. The material stop 88 may be locked tothe measuring rod 86 to prevent further movement when cutting thematerial. The material stop 88 can be rotated between a stoppingposition and a free position. In the stopping position, the materialstop 88 engages the material and prevents the material from movinglongitudinally along the cutting surface. The material stop 88 is thenrotated upwardly away from the table surface 36 to the free positionthat allows the material to move along the entire length. The rotatingof the material stop 88 may be accomplished by rotating about themeasuring rod 86 or by rotating the measuring rod 86. The subjectinvention may also include material clamps 90 for securing the materialto the table surface 36 as is known in the art of clamps.

As illustrated in FIG. 10, the subject invention also provides the sawtable assembly 20 being portable and convenient for use by a singleuser. In order to be portable, the first table rail 22 and the secondtable rail 24 are pivotable relative to one another such that the tableassembly 20 is foldable. A pair of central rails 92 having proximal anddistal ends 94, 96 extend parallel to and spaced from the first and thesecond table rails 22, 24. The pair of central rails 92 engage thelateral supports 34 to form the table surface 36. A hinge mechanism 98connects the lateral supports 34 to the central rails 92 for allowingthe first and the second table rails 22, 24 to pivot about the centralrails 92. The lateral supports 34 preferably extend between the centralrails 92 and between the central rails 92 and the first and the secondtable rails 22, 24 to form the table surface 36.

In order to fold the first and the second table rails 22, 24, the sawrails 38 are removed from the first and the second table rails 22, 24.The saw rails 38 can then be locked into the folded table and used as ahandle. A pair of wheels 100 engages the central rails 92 for moving thetable assembly 20 when the first and the second table rails 22, 24 arepivoted about the central rails 92. When the table is unfolded, thewheels 100 are below the cutting surface and are out of the way of thecutting operation. The table assembly 20 may also include a base (notshown) and foldable legs (not shown) for supporting the saw tableassembly 20.

Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. The invention may bepracticed otherwise than as specifically described within the scope ofthe appended claims.

1. A portable saw table assembly for cutting a material longitudinally,laterally, and at various angles thereto, said assembly comprising: afirst table rail and a second table rail being parallel and spaced fromeach other and each extending between a proximal end and a distal end; asaw rail moveably supported by said first and said second table railsfor moving longitudinally along said table rails between said proximaland said distal ends; a mounting plate moveably supported by said sawrail to move said mounting plate laterally along said saw rail betweensaid first table rail and said second table rail; a saw plate rotateablysupported by said mounting plate for carrying a saw to cut the material;a guide bar disposed diagonally relative to said first and said secondtable rails and engaging said saw plate to guide said saw platediagonally in response to simultaneous movement of said saw raillongitudinally and said mounting plate laterally; a bar locatorsupported by and slideable along one of said first and second tablerails and engaging said guide bar to position said guide bar diagonally;wherein said bar locator is moveable along one of said first and secondtable rails to position said guide bar at various angles between alateral direction and a longitudinal direction; and an angle railsupported by and extending between said first and second table rails forsupporting said guide bar at various angles.
 2. An assembly as set forthin claim 1 wherein said bar locator is further defined as a pair of barlocators engaging each of said first and said second table rails andbeing slideable along said table rails.
 3. An assembly as set forth inclaim 2 wherein one of said bar locators engages one of said first andsaid second table rails and the other of said bar locators engages saidangle rail for cutting the material at various angles.
 4. An assembly asset forth in claim 2 further comprising a third bar locator engagingsaid angle rail such that said guide bar engages one of said pair of barlocators and said third bar locator.
 5. An assembly as set forth inclaim 4 further comprising posts extending upwardly from said barlocators for engaging and securing said guide bar to said bar locator.6. An assembly as set forth in claim 5 further comprising a lockingmechanism engaging each of said bar locators for locking the position ofsaid bar locators.
 7. An assembly as set forth in claim 6 furthercomprising angle indicators on at least one of said first and saidsecond table rails, said saw rail, and said angle rail for positioningsaid bar locators to achieve a desired angle of cut in the material. 8.An assembly as set forth in claim 7 wherein each of said first and saidsecond table rails and said angle rail further include a slot forreceiving said bar locators.
 9. An assembly as set forth in claims 1wherein said first and said second table rails are further defined ashaving a channel for receiving said saw rail with said saw railsupported by said channel.
 10. An assembly as set forth in claim 9wherein said saw rail is further defined as a pair of saw rails.
 11. Anassembly as set forth in claim 10 wherein said pair of saw rails isslideably received within said channel of said first and said secondtable rails.
 12. An assembly as set forth in claim 11 wherein said pairof saw rails is removeable from said channel of said first and saidsecond table rails.
 13. An assembly as set forth in claim 1 furthercomprising a plate clamp to clamp said mounting plate and to preventlateral motion of said mounting plate while moving said saw raillongitudinally.
 14. An assembly as set forth in claim 1 furthercomprising a latch mechanism to secure said saw plate at an angle and toprevent said saw plate from rotating.
 15. An assembly as set forth inclaim 1 wherein said guide bar further defines a groove for engagingsaid saw plate.
 16. An assembly as set forth in claim 15 wherein saidsaw plate further comprises a connector for engaging said groove of saidguide bar to move said saw plate diagonally.
 17. A portable saw tableassembly for cutting a material longitudinally, laterally, and atvarious angles thereto, said assembly comprising: a first table rail anda second table rail being parallel and spaced from each other and eachextending between a proximal end and a distal end; a saw rail moveablysupported by said first and said second table rails for moving alongsaid table rails between said proximal and said distal ends; a mountingplate moveably supported by said saw rail to move said mounting platelaterally along said saw rail between said first table rail and saidsecond table rail; a saw plate supported by said mounting plate forcarrying a saw to cut the material; a guide bar disposed diagonallyrelative to said first and said second table rails and guiding said sawplate diagonally in response to simultaneous movement of said saw railand said mounting plate; a bar locator supported by said first andsecond table rails and engaging said guide bar to position said guidebar diagonally; wherein said bar locator is moveable relative to saidfirst and second table rails to position said guide bar at variousangles between a lateral direction and a longitudinal direction; and anangle rail supported by and extending between said first and secondtable rails for supporting said guide bar at various angles.
 18. Anassembly as set forth in claim 17 wherein said bar locator is furtherdefined as a pair of bar locators engaging each of said first and saidsecond table rails and being slideable along said table rails.
 19. Anassembly as set forth in claim 18 wherein one of said bar locatorsengages one of said first and said second table rails and the other ofsaid bar locators engages said angle rail for cutting the material atvarious angles.
 20. An assembly as set forth in claim 18 furthercomprising a third bar locator engaging said angle rail such that saidguide bar engages one of said pair of bar locators and said third barlocator.
 21. An assembly as set forth in claims 17 wherein said firstand said second table rails are further defined as having a channel forreceiving said saw rail with said saw rail supported by said channel.22. An assembly as set forth in claim 17 further comprising a latchmechanism to secure said saw plate at an angle and to prevent said sawplate from rotating.